A.O. Smith Solar Storage Tank Water Heater User manual

1
Solar Storage Tank
Water Heater
Installation
Instructions and
Use&CareGuide
To obtain technical, warranty or service assistance during or
after the installation of this solar storage tank water heater,
reference the phone number on the warranty sheet that ships
with the water heater.
When calling for assistance, please have the following
information ready:
1. Model number
2. Product number
3. Serial number
4. Date of installation
5. Place of Purchase
Solar Storage Tank Water Heater Safety .........................................2
Installing Your Solar Storage Tank Water Heater ..........................3-9
Unpacking Instructions .......................................................3
Location Requirements .......................................................4
Electrical Requirements ...................................................4-5
Water System Piping........................................................6-9
Installation Checklist ...........................................................9
Operating Your Solar Storage Tank Water Heater.....................10-12
Water Temperature Regulation .........................................10
Adjusting the Thermostat................................................... 11
Operational Conditions ......................................................12
Maintenance of Your Solar Storage Tank Water Heater............13-14
Trouble Shooting Chart ..................................................................14
Repair Parts Illustration ..................................................................15
Thermostat Wiring Chart and Diagram ..........................................16
Table of Contents PAGE
315040-001
November 2011
LOW LEAD
C
O
MPLIANT

2
Your safety and the safety of others are very important.
We have provided many important safety messages in this manual and on your appliance. Always read and obey all
safety messages.
This is the safety alert symbol.
This symbol alerts you to potential hazards that can kill or hurt you and others.
All safety messages will follow the safety alert symbol and either the word “DANGER” or
“WARNING.” These words mean:
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
All safety messages will tell you what the potential hazard is, tell you how to reduce the chance of injury, and tell you
what can happen if the instructions are not followed.
Important Safety Instructions
CAUTION: Hydrogen gas is produced in a hot water system served by this heater that has not been used for a long
period of time (2 weeks or more). Hydrogen gas is extremely flammable. To reduce the risk of injury under these
conditions, it is recommended that the hot water faucet be opened for several minutes at the kitchen sink before
using any electrical appliance connected to the hot water system. When hydrogen is present, there will probably be
an unusual sound such as air escaping through the pipe as the water begins to flow. There should be no smoking or
open flame near the faucet at the time it is open.
The California Safe Drinking Water and Toxic Enforcement Act requires the Governor of California to publish a list of
substances known to the State of California to cause cancer, birth defects, or other reproductive harm, and requires
businesses to warn of potential exposure to such substances.
WARNING: This product contains a chemical known to the State of California to cause cancer, birth defects, or other
reproductive harm.
This appliance can cause low-level exposure to some of the substances included in the Act.
This product is certified to comply with a maximum weighted average of 0.25% lead content as required in some areas.
WATER HEATER SAFETY

3
INSTALLING YOUR WATER HEATER
Consumer Information
This solar storage tank water heater should be installed in
accordance with the local code authority having jurisdiction,
the power company or electric utility, and this installation
manual. In the absence of local code requirements, follow
the regulations set forth in the current edition of The
National Electric Code, NFPA 70. The National Electric
Code is available from the following:
National Fire Protection Association
1 Batterymarch Park
Quincy, MA 02269
American National Standards Institute
1430 Broadway
New York, NY 10018
Check your phone listings for the local authorities having
jurisdiction over your installation.
Consumer Responsibilities
This manual has been prepared to acquaint you with
the installation, operation and maintenance of your solar
storage tank water heater and to provide important safety
information in these areas.
We urge you to read all of the instructions thoroughly
before attempting the installation or operation of this solar
storage tank water heater. This manual should be kept for
future reference.
The manufacturer of this solar storage tank water heater
will not be liable for any damages caused by failure to
comply with the installation and operating instructions
outlined in this manual.
If you lack the necessary skills required to properly install
this solar storage tank water heater or you have difficulty
following the directions, you should not proceed but have
a qualified person perform the installation of this solar
storage tank water heater.
Examples of a qualified person include: licensed plumbers,
authorized gas company personnel, and authorized
service personnel.
Massachusetts code requires this solar storage tank water
heater to be installed in accordance with Massachusetts
248-CMR 2.00: State Plumbing Code and 248-CMR 5.00.
A data plate identifying your solar storage tank water heater
can be found adjacent to the element door. When referring
to your solar storage tank water heater always have the
information listed on the data plate readily available.
Retain your original receipt as proof of purchase.
Unpacking the Water Heater
Removing Packaging Materials
IMPORTANT: Do not remove any permanent instructions,
labels, or the data label from either the outside of the solar
storage tank water heater or on the inside of solar storage
tank water heater panels.
• Remove exterior packaging and place installation
components aside.
• Inspect all parts for damage prior to installation and
start-up.
• Completely read all instructions before attempting to
assemble and install this product.
• After installation, dispose of/recycle all packaging
materials.
WARNING
Excessive Weight Hazard
Use two or more people to move and install
water heater.
Failure to do so can result in back or
other injury.

4
Location Requirements
Site location
Select a location near the center of the water piping system.
The solar storage tank water heater must be installed indoors
and in a vertical position on a level surface.
The solar storage tank water heater should be located in an
area not subject to freezing temperatures. Solar storage tank
water heaters located in unconditioned spaces (i.e., attics,
basements, etc.) may require the water piping and drain piping
to be insulated to protect against freezing. The drain and
controls must be easily accessible for operation and service.
Keep combustibles such as boxes, magazines, clothes, etc.,
away from the solar storage tank water heater area.
This solar storage tank water does not have sufficient
capacity for use with a spa or hot tub.
NOTE: Local codes and requirements in your area may
require the installation of your solar storage tank water to
be accomplished in a way such that the bottom element is
elevated from the floor at least 18 inches.
IMPORTANT: The solar storage tank water should be located
in an area where leakage of the tank or connections will not
result in damage to the area adjacent to the solar storage tank
water or to lower floors of the structure. Due to the normal
corrosive action of the water, the tank will eventually leak after
an extended period of time. Also any external plumbing leak,
including those from improper installation, may cause early
failure of the tank due to corrosion if not repaired. If the owner/
operator is uncomfortable with making the repair a qualified
person should be contacted. A suitable drain pan should be
installed under the solar storage tank water as shown below,
to help protect the property from damage which may occur
from condensate formation or leaks in the piping connections
or tank. The drain pan must limit the water level to a maximum
depth of 2-1/2 inches and be two inches wider than the heater
and piped to an adequate drain. Locate the solar storage tank
water near a suitable indoor drain. Outside drains are subject
to freezing temperatures which can obstruct the drain line.
The piping should be at least 3/4” ID and pitched for proper
drainage. Under no circumstance will the manufacturer or
seller of this solar storage tank water be held liable for any
water damage which is caused by your failure to follow these
instructions.
2 1/2” MAX
PIPE TO
ADEQUATE
DRAIN
AT LEAST 2” INCHES GREATER
THAN THE DIAMETER OF THE
WATER HEATER.
FIGURE 1
RESIDENTIAL GARAGE
INSTALLATION
VEHICLE
STOP
DRAIN
SUITABLE
DRAIN
PAN
NOTE: The solar storage tank water heater shall be located
so it is not subject to physical damage by moving vehicles
or area flooding.
State of California
NOTE: For California installation, this solar storage tank
water heater must be braced, anchored, or strapped to avoid
falling or moving during an earthquake. Correct installation
procedure instructions may be obtained from California’s
Office of the State Architect, 1102 Q street, Suite 5100,
Sacramento, CA 95811. Instructions can also be downloaded
to your computer at www.dsa.dgs.ca.gov/Pubs.
Electrical Requirements
WARNING
Electric Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electrical shock.
WARNING
Fire Hazard
Use proper size solid copper
wire.
Use a UL listed or
CSA approved strain relief.
Connect ground wire to green
ground screw.
Failure to do so can result in
death, fire, or electrical shock.

5
If you lack the necessary skills required to properly install
the electrical wiring to this solar storage tank water heater,
do not proceed but have a qualified electrician perform the
installation.
When making the electrical connections, always make sure:
• The electrical supply has the proper overload fuse or
breaker protection.
• Wire sizes and connections comply with all applicable
codes.
• Wiring is enclosed in approved conduit (if required by local
codes).
• The solar storage tank water heater and electrical supply
are properly grounded.
Important: Do not use an extension cord to supply power
to this solar storage tank water heater. Be sure the power
supply is completely grounded before making connections.
Figures 4, 5, and 6 are provided as reference drawings
for the 120/240v 2-wire models only. Always reference the
wiring diagram located on the solar storage tank water
heater for the correct electrical connections and connect
the electrical supply to the solar storage tank water heater
in accordance with local utility requirements and codes.
When installing the electrical wiring to the solar storage
tank water heater:
1. Be sure tank is completely filled with water before
making any electrical connections. (See Figure 2)
Notice: Applying electrical power to elements that are not
submerged in water will destroy them. The manufacturer
will not warranty any elements damaged in this manner.
FIGURE 2
HEATING ELEMENT
2. Disconnect the electric power.
3. Loosen the screw holding the junction box cover to the
top of the solar storage tank water heater and set aside.
4. Connect the electrical supply to the solar storage tank
water heater in accordance with local utility requirements
and codes.
A standard 1/2 inch opening has been made in the junction
box for conduit connections.
5. Connect ground wire to green ground screw in the junction
box of the solar storage tank water heater. Reinstall the
junction box cover.
Sensor (Furnished by Installer)
Wires are provided from the sensor mounting stud to the
top of the solar storage tank. Attach the tank sensor to
these wires and mount the sensor to the solar storage tank
using the stud provided. The stud is located behind the
lower electrical access cover (See Figure 3). Connect the
two wires that exit through the top of the solar storage tank
enclosure to the solar control. These wires are designed to
be connected to an NEC CLASS II circuit only.
ELEMENT
PLUG
WIRES TO TOP OF
HEATER
SENSOR
MOUNTING
STUD
FIGURE 3
SENSOR MOUNTING STUD
FIGURE 4
120/240V 2-WIRE MODELS
JUNCTION BOX
COVER
GROUND
WIRE CONDUIT
WHITE WIRE (120V MODELS)
RED WIRE (240V MODELS) BLACK WIRE
GREEN
GROUND
SCREW
BLACK
WHITE
APPROVED CONNECTORS
FIGURE 5
WIRING DIAGRAM
120V MODELS ONLY OVERLOAD
PROTECTION
NEUTRAL
HOT
CIRCUIT
BREAKER
TO 120/160V
POWER SUPPLY
ELECTRICAL
SERVICE GROUND
GROUND
SCREW
BLACK
RED
APPROVED CONNECTORS
FIGURE 6
WIRING DIAGRAM
208/240V MODELS ONLY OVERLOAD
PROTECTION
TO 208/240V
@60Hz
1 PHASE
POWER SUPPLY
ELECTRICAL
SERVICE GROUND
L1
L2
CIRCUIT
BREAKER
GROUND
SCREW

6
Water System Piping
FIGURE 7
JACKET TOP WATER CONNECTION LOCATIONS
COLD INLET
ANODE
SOLAR IN (DOWN)*
SOLAR OUT (UP)*
119
GALLON
ONLY
HOT OUTLET
TEMPERATURE AND
PRESSURE RELIEF VALVE
*SEE FIGURE 8 FOR SIDE SOLAR CONNECTIONS (OPTIONAL). YOU MAY USE
EITHER THE TOP OR THE SIDE SOLAR CONNECTIONS.
Piping, fittings, and valves should be installed according to
the installation drawing (Figure 8). If the indoor installation
area is subject to freezing temperatures, the water piping
must be properly insulated.
IN A CLOSED SYSTEM
USE EITHER:
1. THERMAL EXPANSION TANK
2. PRESSURE RELIEF VALVE
PRESSURE REDUCING
VALVE WITH BYPASS
COLD WATER
INLET
COLD WATER
INLET VALVE
MIXED HOT
WATER
OUTLET
UNION
TEMPERATURE AND
PRESSURE RELIEF VALVE
DISCHARGE LINE
(DO NOT CAP OR PLUG)
DRAIN LINE
3/4 INCH ID
MINIMUM
DRAIN
SUITABLE DRAIN PAN
2-1/2 INCH DEPTH MAX.
1 INCH
MIN.
MASSACHUSETTS:
INSTALL A VACUUM
RELIEF IN COLD
WATER LINE PER
SECTION 19 MGL 142.
FIGURE 8
WATER PIPING INSTALLATION
MIXING
VALVE SOLAR OUT (UP)*
SOLAR IN (DOWN)*
6 INCH MAXIMUM AIR GAP
BETWEEN THE END OF THE
DISCHARGE LINE AND DRAIN
SOLAR IN (From Collector)*
* YOU MAY USE EITHER THE TOP OR THE SIDE SOLAR CONNECTIONS.
SOLAR OUT (To Collector)*
The water supply pressure should not exceed 80 psi. If this
occurs, a pressure reducing valve with a bypass should be
installed in the cold water inlet line. This should be placed
on the supply to the entire house in order to maintain equal
hot and cold water pressures.
IMPORTANT:
• Heat must not be applied to the water fittings on the heat-
er as they may contain nonmetallic parts. If solder con-
nections are used, solder the pipe to the adapter before
attaching the adapter to the hot and cold water fittings.
• Always use a good grade of joint compound and be cer-
tain that all fittings are tight.
Piping Installation
1. Install the water piping and fittings as shown in
Figure 8. Connect the cold water supply (3/4” NPT) to
the fitting marked “Cold Water In”. Connect the hot water
supply (3/4” NPT) to the fitting marked “Hot Water Out”.
IMPORTANT: Some models may contain energy saving
heat traps to prevent the circulation of hot water within the
pipes. Do not remove these inserts.
2. The installation of unions in both the hot and cold water
supply lines are recommended for ease of removing the
solar storage tank water heater for service or replacement.
3. The manufacturer of this solar storage tank water heater
recommends installing a mixing valve or an anti-scald
device in the domestic hot water line as shown in Figure
9. These valves reduce the point-of-use temperature of
the hot water by mixing cold and hot water and are readily
available. Contact a licensed plumber or the local plumbing
authority. Install a spring check valve in the cold water inlet
to the mixing valve (See Figure 9). Connect the piping
that will carry the water from the solar storage tank to the
solar collectors, then to the fitting marked “SOLAR OUT.”
Connect the return line from the solar collectors to the
fitting marked “SOLAR IN.” You may use either the top
connections or the side connections (see Figure 8).
IMPORTANT: Cap or plug the solar connections that are
not used.
FIGURE 9
MIXING VALVE
TOP WATER CONNECTIONS
SOLAR IN (To Collector)
COLD
WATER
INLET
MIXING
VALVE TO
FIXTURES
MIXING VALVE
(SET TO 120°F)
SOLAR OUT (To Collector)
SPRING
CHECK VALVE
MIXED
HOT
WATER
OUTLET
4. Recirculation return lines should be connected to an
auxiliary solar storage tank water heater (see Figure
10, Page 7). DO NOT connect recirculation lines to
the solar storage tank. Recirculation pumps should be
controlled by a timer which will stop circulation at night
or any time hot water is not being used.
5. If components in the solar control system have
maximum working pressures that are lower than the
maximum water supply pressure, a pressure reducing
valve with an integral strainer and by-pass should
be installed in a cold water supply line. The pressure

7
reducing valve must be adjusted to the lowest working
pressure of the solar control components.
6. If installing the solar storage tank water heater in a
closed water system, install an expansion tank as
specified under “Closed System / Thermal Expansion.”
7. Install a shut off valve in the cold water inlet line. It
should be located close to the solar storage tank water
heater and be easily accessible. Know the location of
this valve and how to shut off the water to the heater.
8. Install a temperature and pressure relief valve and
discharge line in the opening marked “T & P RELIEF
VALVE”. Install as specified under “Temperature and
Pressure Relief Valve.”
9. After piping has been properly connected to the solar
storage tank water heater, open the nearest hot water
faucet and allow the tank to completely fill with water.
To purge the lines of any excess air and sediment,
keep the hot water faucet open for 3 minutes after a
constant flow of water is obtained. Close the faucet and
check all connections for leaks.
MIXING VALVE PLUMBING
AUXILIARY WATER HEATER SOLAR STORAGE TANK
ELECTRIC ASSISTED
SOLAR STORAGE TANK
FIGURE 10
HOT COLD HOT COLD
HOT COLD
RECIRCULATION
RETURN
SPRING CHECK VALVE
COLD WATER SUPPLY
MIXING VALVE
MIXED HOT
WATER OUTLET
SPRING CHECK VALVE
COLD
WATER
SUPPLY
MIXING VALVE
MIXED HOT
WATER
OUTLET
SOLAR IN
(FROM COLLECTOR)
SOLAR OUT
(TO COLLECTOR)
SOLAR STORAGE W/AUXILLARY BACK-UP CONFIGURATION SOLAR STORAGE CONFIGURATION
General Information
Please note the following:
DO NOT install this solar storage tank water heater with
iron piping. The system should be installed only with new
piping that is suitable for potable (drinkable) water such as
copper, CPVC, or polybutylene. DO NOT use PVC water
piping.
DO NOT use any pumps, valves, or fittings that are not
compatible with potable water.
DO NOT use valves that may cause excessive restriction
to water flow. Use full flow ball or gate valves only.
DO NOT use 50/50 tin-lead solder (or any lead based
solder) in potable water lines. Use 95/5 tin-antimony or
other equivalent material.
DO NOT tamper with the thermostat, heating elements,
electrical connections, or temperature and pressure relief
valve. Tampering voids all warranties. Only qualified
technicians should service these components.
DO NOT use with piping that has been treated with
chromate’s, boiler seal, or other chemicals.
DO NOT add any chemicals to the system piping which will
contaminate the potable water supply.

8
WARNING
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
qualified person replace it.
Examples of a qualified person include:
licensed plumbers, authorized gas
company personnel, and authorized
service personnel.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
FIGURE 11
TEMPERATURE AND PRESSURE
RELIEF VALVE INSTALLATION
TEMPERATURE AND
PRESSURE RELIEF
VALVE
DISCHARGE LINE
3/4 INCH MIN.
DO NOT CAP OR PLUG
6 INCH
MAXIMUM
AIR GAP
DRAIN PAN
DRAIN
Closed System/Thermal Expansion
As water is heated, it expands (thermal expansion). In a
closed system, the volume of water will increase. As the
volume of water increases, there will be a corresponding
increase in water pressure due to thermal expansion.
Thermal expansion can cause premature tank failure
(leakage). This type of failure is not covered under the
limited warranty. Thermal expansion can also cause
intermittent temperature-pressure relief valve operation:
water discharged from the valve due to excessive
pressure build up. The temperature-pressure relief
valve is not intended for the constant relief of thermal
expansion. This condition is not covered under the limited
warranty.
A properly-sized thermal expansion tank should be
installed on all closed systems to control the harmful
effects of thermal expansion. Contact a plumbing service
agency or your retail supplier regarding the installation of
a thermal expansion tank.
Do not plug the temperature and pressure relief
valve.
Solar Control Systems
Solar control systems used with this solar storage tank
must not allow temperatures in the tank to exceed 180°F
and must protect the system from freeze damage when
the temperatures approach freezing.
This solar storage tank does not contain a heat
exchanger; therefore, only potable (drinkable) water may
be allowed to enter the tank. If this solar storage tank is
installed in a system using any heat transfer fluid other
than potable water, a separate heat exchanger must be
installed. Heat exchangers used in conjunction with this
solar storage tank must provide adequate protection of
contamination of potable water by toxic fluids used in
heat exchange systems.
If this water heater is used as a solar storage heater or as
a backup for the solar storage system, the water supply
temperatures to the water heater tank may be in excess
of 120°F. A mixing valve or other temperature limiting
device should be installed in the water supply line to limit
the supply temperature to 120°F.
Temperature and Pressure Relief Valve
For protection against excessive pressures and
temperatures, a temperature and pressure relief valve must
be installed in the opening marked “T & P RELIEF VALVE”
(See Figure 11).
Caution: To reduce the risk of excessive pressures and
temperatures in this solar storage tank water heater,
install temperature and pressure relief protective
equipment required by local codes, but no less than
a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory that
maintains periodic inspection of the production of listed
equipment or materials, as meeting the requirements
for Relief Valves and Automatic Shutoff Devices for Hot
Water Supply Systems, ANSI Z21.22 - current edition.

9
This valve must be marked with the maximum set
pressure not to exceed the marked maximum working
pressure of the solar storage tank water heater. Install
the valve into an opening provided and marked for this
purpose in the solar storage tank water heater, and
orient it or provide tubing so that any discharge from the
valve exits only within 6 inches above, or at any distance
below, the structural floor, and does not contact any
live electrical part. The discharge opening must not be
blocked or reduced in size under any circumstance.
Important: Only a new temperature and pressure relief
valve should be used with your solar storage tank water
heater. Do not use an old or existing valve as it may be
damaged or not adequate for the working pressure of
the new solar storage tank water heater. Do not place
any valve between the relief valve and the tank.
The Temperature & Pressure Relief Valve:
• Must not be in contact with any electrical part.
• Must be connected to an adequate discharge line.
• Must not be rated higher than the working pressure
shown on the data plate of the solar storage tank
water heater.
The Discharge Line:
• Must not be smaller than the pipe size of the relief
valve or have any reducing coupling installed in
the discharge line.
• Must not be capped, blocked, plugged or contain
any valve between the relief valve and the end of the
discharge line.
• Must terminate a maximum of six inches above
a floor drain or external to the building. In cold
climates, it is recommended that the discharge
pipe be terminated at an adequate drain inside the
building.
• Must be capable of withstanding 250°F (121°C)
without distortion.
• Must be installed to allow complete drainage of both
the valve and discharge line.
Installation Check List
Solar storage tank water heater
Location
• Centrally located with the water piping system.
• Located indoors and in a vertical position. Protected
from freezing temperatures.
• Provisions made to protect the area from water
damage. Suitable drain pan installed and piped to an
adequate drain.
• Sufficient room to service the solar storage tank water
heater.
Water System Piping
• Temperature and pressure relief valve properly
installed with a discharge line run to an open drain and
protected from freezing.
• All piping properly installed and free of leaks.
• Heater completely filled with water. (See Figure 2)
• Closed system pressure buildup precautions installed.
• Mixing valve installed per manufacturer’s instructions.
Electrical Connections
• Wiring and connections comply with all applicable
codes.
• Solar storage tank water heater and electrical supply
are properly grounded.
• Proper overload fuse or circuit breaker protection
installed.

10
OPERATING YOUR WATER HEATER
Before Using
1. Make sure the solar storage tank water heater has
been properly installed. See “Installing Your Water
Heater” section.
2. Completely fill the tank with water. (See Figure 2)
3. After the solar storage tank water heater tank is
completely filled with water, connect electrical power to
the solar storage tank water heater.
4. Read the “Water Temperature Regulation” section of
this manual. If the instructions are not clear, contact a
qualified person.
5. Adjust the thermostat to the desired temperature
setting as described under “Adjusting the Thermostat/
High Limit Control” section.
IMPORTANT: Do not attempt to operate this solar storage
tank water heater if the thermostat(s), or surrounding
insulation has been exposed to water in any way.
Immediately call a qualified person to inspect the solar
storage tank water heater and replace any thermostat or
insulation that has been exposed to water.
Do not attempt to repair these parts. Solar storage tank
water heaters subjected to flood conditions or any time
the thermostat(s) have been submerged in water require
replacement of the entire solar storage tank water heater.
Safety Shut-off
This solar storage tank water heater is designed
to automatically shut-off in the event that the water
temperature exceeds 170°F or 77°C (190°F or 88°C in
LDCE Models). A high limit control switch is used to shut off
the power to the elements if the water temperature exceeds
170°F or 77°C (190°F or 88°C in LDCE Models). The high
limit control can be reset by firmly pushing in the red reset
button located on the thermostat. Follow the instructions
under “Adjusting the Thermostat/High Limit Control”,
section to properly reset the high limit control. If the high
limit control switch continues to shut-off the water heater
contact a qualified person for service.
Water Temperature Regulation
Water temperature over 125°F can cause
severe burns instantly or death from scalds.
Children, disabled and elderly are at highest
risk of being scalded.
Feel water before bathing or showering.
Temperature limiting valves are available.
WARNING
The thermostat is adjusted to a temperature setting
of 120°F or lower when it is shipped from the factory.
Water temperature can be regulated by adjusting
the thermostat to the preferred setting as shown in
“Adjusting the Thermostat /High Limit Control.” The
preferred starting point is 120°F. There is a hot water
scald potential if the thermostat is set too high.
IMPORTANT: Adjusting the thermostat past 120°F on
the thermostat will increase the risk of scald injury in the
times shown below.
Water
Temperature °F
Time for 1st
Degree Burn
(Less Severe Burns)
Time for
Permanent Burns
2nd & 3rd Degree
(Most Severe Burns)
110
116
116
122
131
140
149
154
(normal shower temp.)
(pain threshold)
35 minutes
1 minute
5 seconds
2 seconds
1 second
instantaneous
45 minutes
5 minutes
25 seconds
5 seconds
2 seconds
1 seconds
(U.S. Government Memorandum, C.P.S.C., Peter L. Armstrong, Sept. 15,1978)
NOTE: During low demand periods when hot water is not
being used, a lower thermostat setting will reduce energy
losses and may satisfy your normal hot water needs.
If hot water use is expected to be more than normal, a
higher thermostat setting may be required to meet the
increased demand.
When leaving your home for extended periods
(vacations, etc.) turn the thermostat to its lowest setting.
This will maintain the water at low temperatures with
minimum energy losses and prevent the tank from
freezing during cold weather.

11
Adjusting the Thermostat/High Limit Control
This water heater is equipped with one or more adjustable temperature regulating thermostats and a manual reset high
limit control. The following procedures must be performed when changing the temperature of the stored water or resetting
the high limit control.
Before attempting to adjust the thermostat, make sure that you read and understand the “Water Temperature
Regulation” section. Any other adjustments must be made by qualified service personnel.
1. Disconnect the electric power.
2. Remove the access cover and fold up the insulation from the thermostat. Do not remove the plastic cover.
3. Using a screwdriver to adjust the thermostat pointer, set the thermostat to the desired water temperature.
Be sure the RED reset button (High Limit Control) is pushed in. If needed, push in firmly to reset.
4. Fold the insulation down, making sure the thermostat is well covered. Replace the access cover.
5. Reconnect power.
ACCESS
COVERS
SINGLE ELEMENT
HEATER
FIGURE 12
THERMOSTAT
150°F 90°F
125°F
SCREW
SLOT
THERMOSTAT SETTING
AND ADJUSTMENT
150°F 90°F
125°F
RED RESET BUTTON
SOLAR SENSOR

12
Operational Conditions
Anode Rod/Water Odor
Each water heater contains at least one anode rod, which
will slowly deplete (due to electrolysis) prolonging the life
of the water heater by protecting the glass-lined tank from
corrosion. Adverse water quality, hotter water temperatures,
high hot water usage, hydronic heating devices, and water
softening methods can increase the rate of anode rod
depletion. Once the anode rod is depleted, the tank will start
to corrode, eventually developing a leak.
Certain water conditions will cause a reaction between the
anode rod and the water. The most common complaint
associated with the anode rod is a “rotten egg smell”
produced from the presence of hydrogen sulfide gas
dissolved in the water. IMPORTANT: Do not remove this
anode rod permanently as it will void any warranties.
A special anode rod may be available if water odor or
discoloration occurs. NOTE: This anode rod may reduce
but not eliminate water odor problems. The water supply
system may require special filtration equipment from a water
conditioning company to successfully eliminate all water odor
problems.
Artificially softened water is exceedingly corrosive because
the process substitutes sodium ions for magnesium and
calcium ions. The use of a water softener may decrease the
life of the water heater tank.
The anode rod should be inspected after a maximum of
three years and annually thereafter until the condition of
the anode rod dictates its replacement. NOTE: Artificially
softened water requires the anode
rod to be inspected annually.
The following are typical (but not all)
signs of a depleted anode rod:
• The majority of the rods
diameter is less than 3/8”.
• Significant sections of the
support wire (approx. 1/3 or
more of the anode rod’s length)
are visible.
If the anode rod shows signs of
either or both it should be replaced.
NOTE: Whether reinstalling or
replacing the anode rod, check for
any leaks and immediately correct if
found.
In replacing the anode:
1. Turn off power to the water
heater.
2. Shut off the water supply and open a nearby hot water
faucet to depressurize the water tank.
3. Drain approximately 5 gallons of water from tank
(Refer to the “Draining and Flushing” section for proper
procedures). Close drain valve.
4. Remove old anode rod.
5. Use Teflon®tape or approved pipe sealant on threads
and install new anode rod.
6. Turn on water supply and open nearby hot water faucet
to purge air from water system. Check for any leaks and
immediately correct any if found.
7. Restart the water heater as directed under the
“Operating Your Water Heater” section. See the “Repair
Parts Illustration” section for anode rod location.
®TEFLON is a registered trademark of E.I. Du Pont De Nemours and Company.
Water Heater Sounds
During the normal operation of the water heater, sounds or
noises may be heard. These noises are common and may
result from the following:
1. Normal expansion and contraction of metal parts
during periods of heat-up and cool-down.
2. Sediment buildup in the tank bottom will create
varying amounts of noise and may cause premature
tank failure. Drain and flush the tank as directed under
the “Draining and Flushing” section.
Stratification
Temperature stratification may occur as water from the
solar collectors flows into the water heater tank. Since
this water may be hotter than the thermostat setting, the
temperature at the hot water outlet may be higher than
expected. An anti-scald device is recommended in the hot
water supply line to reduce the risk of scald injury.
Figure 13:
Anode Rod Depletion

13
MAINTENANCE OF YOUR WATER HEATER
Temperature and Pressure
Relief Valve
Manually operate the temperature and pressure relief valve
at least once a year to make sure it is working properly.
To prevent water
damage, the valve
must be properly
connected to a
discharge line which
terminates at an
adequate drain.
Standing clear of the
outlet (discharged
water may be
hot), slowly lift and
release the lever
handle on the
temperature and pressure relief valve to allow the valve to
operate freely and return to its closed position. If the valve
fails to completely reset and continues to release water,
immediately disconnect the electrical power, close the cold
water inlet valve and call a qualified person.
Draining and Flushing
The water heater should be drained if being shut down
during freezing temperatures. It is recommended that the
tank be drained, and flushed every 6 months to remove
sediment which may buildup during operation. To drain the
tank perform the following steps:
Figure 14
Temperature and Pressure
Relief Valve
Manual Relief
Valve
Discharge line to drain
1. Turn off power to the water heater.
2. Open a hot water faucet until water is no longer hot.
3. Close the cold water inlet valve.
4. Connect a hose to the drain valve and terminate it to an
adequate drain or external to the building.
5. Open the water heater drain valve and the nearest
hot water faucet. Allow all the water to drain from the
tank. Flush the tank with water as needed to remove
sediment.
6. Close the drain valve and completely refill the water
heater tank.
CAUTION: Do not turn on power to the water heater
unless it is completely filled with water. To ensure that
the tank is full, open a hot water faucet and allow the
water to run until the air is purged and the water flows
uninterrupted from the faucet.
7. Reconnect electrical power to the water heater.
If the water heater is going to be shut down for an extended
period, the drain valve should be left open.
Heating Element Replacement
WARNING
Electric Shock Hazard
Disconnect power before
servicing.
Replace all parts and panels
before operating.
Failure to do so can result in
death or electrical shock.
Replacement heating elements must be of the same style
and voltage/wattage rating as the ones presently in the
water heater. This information can be found on the flange
or terminal block of the element or on the water heater data
plate.
1. Disconnect the electrical power to the water heater.
2. Drain the water heater as directed in the “Draining
and Flushing” section.
3. Remove the access cover. Fold up the insulation from
the heater element. Remove the plastic thermostat
cover from the thermostat making sure to disengage
the attachment point from the thermostat.
4. Disconnect the electrical wires from the heating
element by loosening the screws (Figure 15).
Remove the screw-in element by turning the element
counterclockwise with a 1-1/2 inch socket wrench.
Remove the existing gasket.
Explosion Hazard
If the temperature and pressure relief valve
is dripping or leaking, have a qualified
person replace it.
Examples of a qualified person include:
licensed plumbers, authorized gas company
personnel, and authorized service
personnel.
Do not plug valve.
Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
WARNING

14
5. Clean the area where the gasket fits to the tank. If
you are replacing the bottom element, remove any
accumulated sediment on the bottom of the tank.
6. Make sure the replacement element has the correct
voltage and wattage rating by matching it to the rating
plate on the water heater. Position the new gasket on
the element and insert it into the water heater tank
(Figure 16). Tighten the element until it is secure by
turning it clockwise with a 1-1/2 inch socket wrench.
7. Close the drain valve. Open the nearest hot water
faucet and allow the tank to fill completely with water.
Spud
Screw-in
Element
Gasket
Thermostat
Holding Bracket
To purge the lines of any excess air and sediment,
keep the hot water faucet open for 3 minutes after a
constant flow of water is obtained.
8. Check for leaks around the element.
9. Reconnect the electrical wires to the element and
securely tighten the screws. Replace the plastic
thermostat cover making sure the attachment points
are engaged on the thermostat.
10. Replace the access cover.
11. Make certain the tank is filled with water. Applying
electric current to heater elements not submerged in
water will destroy them.
12. Reconnect electrical power to the water heater.
Figure 15
TROUBLESHOOTING CHART
PROBLEM POSSIBLE CAUSE(S) CORRECTIVE ACTION
NO HOT WATER 1. No power to heater
2. High Temperature Limit Switch open
3. Non-Functioning thermostat
1. Turn on electrical switch. Check for blown fuses
or tripped breaker
2. Reset. Check for source of trouble and correct
3. Replace thermostat
INSUFFICIENT HOT WATER 1. Non-Functioning thermostat
2. Non-Functioning element
3. Improper calibration
4. Thermostats set too low
5. Sediment or lime in tank
6. Heater too small for job
7. Wrong piping connections
8. Leaking faucets
9. Wasted hot water
10. Long runs of exposed pipe
11. Hot water piping on outside wall
1. Replace thermostat
2. Replace element
3. Replace thermostat
4. Set thermostats to desired temperature
5. Drain/flush tank. Provide water treatment if needed
6. Install adequately-sized water heater
7. Correct piping
8. Repair faucets
9. Advise customer
10. Insulate piping
11. Insulate piping
HIGH OPERATION COSTS 1. Improper Calibration
2. Thermostats set too high
3. Sediment or lime in tank
4. Heater too small for job
5. Wrong piping connections
6. Leaking faucets
7. Wasted hot water
8. Long runs of exposed piping
9. Hot water piping in exposed wall
1. Replace thermostats
2. Set thermostat to desired setting
3. Drain/flush tank. Provide water treatment if needed
4. Install adequately-sized water heater
5. Correct piping
6. Repair faucets
7. Advise customer
8. Insulate piping
9. Insulate piping
SLOW HOT WATER
RECOVERY
1. Non-Functioning element 1. Replace element
DRIP FROM RELIEF VALVE 1. Excessive water pressure
2. Closed system
1. Check system water pressure. verify 50-60 psi.
Use appropriate pressure reducing valve to set
correct water pressure. Check Thermal
expansion tank.
2. See “Closed System/Thermal Expansion” section
THERMOSTAT DOES NOT
SHUT OFF
1. Non-Functioning thermostat
2. Improper calibration
1. Replace thermostat
2. Replace thermostat
WATER ODOR 1. Sulfides in the water 1. See “Anode Rod/Water Odor” section
Screws
Wires
Element
Figure 16
NOTE: The chart above only applies to the solar storage tank water heater. This storage tank is only one part of the total system. If the
problem does not originate with the storage tank, the chart above cannot isolate the problem. In such cases, a qualified solar technician
should troubleshoot the system.

15
15
REPAIR PARTS ILLUSTRATION
REPAIR PARTS
Repair parts may be ordered through your plumber,
local distributor, home improvement center, or by
calling the phone number on the warranty sheet that
ships with the water heater. When ordering repair parts
always give the following information:
1. Model, serial and product number
2. Item number
3. Parts description
LEGEND
Not supplied on some models
Electrical Assisted only
REPAIR PARTS LIST
ITEM
NO. PARTS DESCRIPTION
13
13
12
11
9
8
8
10
5
2
14
16
6
7
3 4
and
1
15
5
5
COLD INLET NIPPLE/DIPTUBE
SOLAR INLET/OUTLET DIPTUBE
ANODE ROD (65 & 80 GALLON 1 ANODE)
ANODE ROD (120 GALLON 2 ANODES)
NIPPLE
TEMPERATURE AND PRESSURE RELIEF VALVE
JUNCTION BOX COVER
ELEMENT GASKET
ELEMENT PLUG
ELEMENT
THERMOSTAT
THERMOSTAT COVER
ELECTRICAL ACCESS COVER
DRAIN VALVE
SENSOR STUD
FLANGE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

16
120
V
WATT
LOAD
BRANCH CIRCUIT SIZING GUIDE
Based on N.E.C. NFPA NO. 70 - 1999
208
V
240
V
Recommend
Over Current
Protection Rating
120
V208
V
240
V
Copper Wire Size
AWG Based on N.E.C.
Table 310 - 16 (60°C)
* Wattages less than 1500 may be wired 14 gage with 15 amp
protection
BLACK
BLACK
L1 L2
FUSED DISCONNECT
OR CIRCUIT BREAKER
RED
THERMOSTAT
&
HIGH LIMIT
CONTROL
WIRING NO. 7
SINGLE ELEMENT HEATER
6603461G
RED
HEATING
ELEMENT
GROUND
SCREW
ELECTRICAL
SERVICE
GROUND
WHITE
BLACK
BLACK
HOT
WHITE
THERMOSTAT
&
HIGH LIMIT
CONTROL
NEUTRAL
FUSED DISCONNECT
OR CIRCUIT BREAKER
WIRING NO. 1
SINGLE ELEMENT HEATER
6603461H
HEATING
ELEMENT
GROUND
SCREW
ELECTRICAL
SERVICE
GROUND
THERMOSTAT WIRING DIAGRAM
1500* 15 15 15 12 14 14
2000 20 15 15 10 14 14
2500 30 15 15 10 14 14
3000 30 20 15 8 12 12
3500 - 20 20 - 10 12
4000 - 25 20 - 10 10
4500 - 30 25 - 10 10
5000 - 30 30 - 10 10
5500 - 35 30 - 8 10
6000 - 35 30 - 8 8
9000 - 50 45 - 6 6
12000 - 70 60 - 3 4
Important: Read and understand the Electrical Requirements section on page 4.